Fuel Tank Replacement Passenger/Cargo Van

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Loosen the fuel fill hose clamp.
6. Disconnect the fuel fill hose from the fuel tank.
7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
9. Disconnect the chassis fuel feed pipe at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .



10. With the aid of an assistant, support the fuel tank.
11. Remove the attaching bolts (4) from the fuel tank strap .
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.



17. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
18. Remove the fuel fill hose from the fuel tank.
19. Remove the fuel tank from the fuel tank shield.

1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel fill hose to the fuel tank.

Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).

4. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .



5. With the aid of an assistant, position and support the fuel tank.
6. Raise the fuel tank slightly.
7. Connect the electrical connectors to the fuel sender and the fuel pressure sensor .
8. Raise the tank fully.
9. Install the fuel tank straps (3).

Important: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

10. Install the new attaching bolts (4) to the fuel tank strap .

Tighten
Tighten the bolts to 20.5 N·m (15 lb ft).

11. Connect the chassis fuel feed pipe to the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
12. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .



13. Connect the fuel fill hose to the fuel fill pipe.

Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).

14. Lower the vehicle.
15. Refill the fuel tank.
16. Tighten the fuel filler cap.
17. Connect the negative battery cable.
18. Inspect for leaks:

18.1.

Turn ON the ignition for 2 seconds.

18.2.

Turn OFF the ignition for 10 seconds.

18.3.

Turn ON the ignition.

18.4.

Inspect for fuel leaks.